U.S. patent application number 10/870746 was filed with the patent office on 2005-12-22 for corner flashing.
Invention is credited to Boivin, Kathleen Celeste, Mileti, Robert J..
Application Number | 20050279044 10/870746 |
Document ID | / |
Family ID | 35479123 |
Filed Date | 2005-12-22 |
United States Patent
Application |
20050279044 |
Kind Code |
A1 |
Mileti, Robert J. ; et
al. |
December 22, 2005 |
Corner flashing
Abstract
A window corner flashing device includes a first and a second
member. The first member includes a first section which is disposed
adjacent a second section and is angled thereto. The first section
and second section have a first edge and second edge, respectively,
wherein the first member includes a first continuous flange
disposed along the first and second edges of the first and second
sections, respectively. The second member includes a first section
having a third edge and a second section having a fourth edge. The
second member further includes a first continuous mating edge which
is disposed along the third and the fourth edge thereof. The first
member is affixed to the second member by having the first
continuous flange permanently affixed to the first continuous
mating edge.
Inventors: |
Mileti, Robert J.;
(Torrington, CT) ; Boivin, Kathleen Celeste;
(Rehoboth, MA) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
35479123 |
Appl. No.: |
10/870746 |
Filed: |
June 17, 2004 |
Current U.S.
Class: |
52/580 |
Current CPC
Class: |
E06B 1/62 20130101; E06B
2001/628 20130101 |
Class at
Publication: |
052/580 |
International
Class: |
E04C 003/00; E04C
003/30 |
Claims
The invention claimed is:
1. A flashing device comprising: a first member having a first
section disposed adjacent a second section and angled thereto, the
first section and second section having a first edge and second
edge, respectively, the first member further comprising a first
continuous flange disposed along the first and second edges of the
first and second sections, respectively; and a second member
comprising a first section having a third edge and a second section
having a fourth edge, the second member further comprising a first
continuous mating edge disposed along the third and a fourth edge
thereof; wherein the first continuous flange is permanently affixed
to the first continuous mating edge.
2. The flashing device of claim 1, wherein the first flashing
member is generally L-shaped.
3. The flashing device of claim 2, wherein the second flashing
member is generally L-shaped.
4. The flashing device of claim 1, wherein the first continuous
flange is thermally bonded to the first continuous mating edge.
5. The flashing device of claim 1, wherein the first and second
flashing members are polyolefin.
6. The flashing device of claim 5, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
7. A flashing device for doors, windows and the like comprising: a
first flashing member comprising a first section including a first
edge and a second section including a second edge, the first and
second edges disposed adjacently to define a first continuous edge
therealong, the first section disposed at a first angle with
respect to the second section; a second flashing member including a
third and a fourth edge, the third edge disposed at a second angle
with respect to the fourth edge, the second angle generally equal
to the first angle, the third and fourth edges adjacently disposed
to define a second continuous edge; and a continuous flange
disposed along at least one of the first continuous edge or the
second continuous edge; wherein the continuous flange disposed
along the at least one of the first continuous edge or the second
continuous edge is affixed to the other of the second continuous
edge or the first continuous edge.
8. The flashing device of claim 7, wherein the first flashing
member is generally L-shaped.
9. The flashing device of claim 8, wherein the second flashing
member is generally L-shaped.
10. The flashing device of claim 7, wherein the first continuous
flange is thermally bonded to the first or second continuous
edge.
11. The flashing device of claim 7, wherein the first and second
flashing members are polyolefin.
12. The flashing device of claim 11, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
13. The flashing device of claim 7, wherein the flange extends over
a portion of the other of the second continuous edge or the first
continuous edge.
14. A flashing device for doors, windows and the like comprising: a
first flashing member comprising a first section including a first
edge, and a second section including a second edge, the first and
the second edges disposed adjacently to define a first continuous
edge therealong, the first section disposed generally orthogonally
with respect to the second section; a second flashing member
including a third and a fourth edge, the third edge disposed
generally orthogonal to the fourth edge, the third and fourth edges
adjacently disposed to define a second continuous edge therealong;
and a continuous flange disposed along at least one of the first
continuous edge or the second continuous edge; wherein the
continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous edge
such that the first member may be disposed generally orthogonal to
the second member.
15. The flashing device of claim 14, wherein the first flashing
member is generally L-shaped.
16. The flashing device of claim 15, wherein the second flashing
member is generally L-shaped.
17. The flashing device of claim 14, wherein the continuous flange
is thermally bonded to the first or second continuous edge.
18. The flashing device of claim 14, wherein the first and second
flashing members are polyolefin.
19. The flashing device of claim 18, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
20. The flashing device of claim 14, wherein the flange extends
over a portion of the other of the second continuous edge or the
first continuous edge.
21. A flashing device for doors, windows and the like comprising: a
first flashing member comprising a first section including a first
edge, and a second section including a second edge, the first and
second edges disposed adjacently to define a first continuous edge
therealong, the first section disposed at a first angle with
respect to the second section; a second flashing member comprising
a third section including a third edge, and a fourth section
including a fourth edge, the third and fourth edges disposed
adjacently to define a second continuous edge therealong, the third
edge disposed at a second angle with respect to the fourth edge;
and a continuous flange disposed along at least one of the first
continuous edge or the second continuous edge; wherein the
continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous
edge.
22. The flashing device of claim 21, wherein the first flashing
member is generally L-shaped.
23. The flashing device of claim 22, wherein the second flashing
member is generally V-shaped.
24. The flashing device of claim 21, wherein the second flashing
member is generally V-shaped.
25. The flashing device of claim 21, wherein the continuous flange
is thermally bonded to the first or second continuous edge.
26. The flashing device of claim 21, wherein the first and second
flashing members are polyolefin.
27. The flashing device of claim 26, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
28. The flashing device of claim 21, wherein the flange extends
over a portion of the other of the second continuous edge or the
first continuous edge.
29. A flashing device for doors, windows and the like comprising: a
first flashing member comprising a first section including a first
edge, and a second section including a second edge, the first and
second edges disposed adjacently to define a first continuous edge
therealong, the first section disposed at a generally orthogonal
angle with respect to the second section; a second flashing member
comprising a third section including a third edge, and a fourth
section including a fourth edge, the third and fourth edges
disposed adjacently to define a second continuous edge therealong,
the third section disposed at a generally orthogonal angle with
respect to the fourth section; and a continuous flange disposed
along at least one of the first continuous edge or the second
continuous edge; wherein the continuous flange disposed along the
at least one of the first continuous edge or the second continuous
edge is affixed to the other of the second continuous edge or the
first continuous edge such that the first member may be disposed
generally orthogonal to at least part of the second member.
30. The flashing device of claim 29, wherein the first flashing
member is generally L-shaped.
31. The flashing device of claim 30, wherein the second flashing
member is generally V-shaped.
32. The flashing device of claim 29, wherein the second flashing
member is generally V-shaped.
33. The flashing device of claim 29, wherein the continuous flange
is thermally bonded to the first or second continuous edge.
34. The flashing device of claim 29, wherein the first and second
flashing members are polyolefin.
35. The flashing device of claim 34, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
36. The flashing device of claim 29, wherein the flange extends
over a portion of the other of the second continuous edge or the
first continuous edge.
37. A method of creating a flashing device for doors, windows and
the like comprising: providing a first flashing member comprising a
first section including a first edge and a second section including
a second edge, the first and second edges disposed adjacently to
define a first continuous edge therealong; bending the first
section to a first angle with respect to the second section;
providing a second flashing member including a third and a fourth
edge, the third edge disposed at a second angle with respect to the
fourth edge, the second angle generally equal to the first angle,
the third and fourth edges adjacently disposed to define a second
continuous edge; forming a continuous flange along at least one of
the first continuous edge or the second continuous edge; and
affixing the continuous flange disposed along the at least one of
the first continuous edge or the second continuous edge to the
other of the second continuous edge or the first continuous
edge.
38. The method of claim 37, wherein the provided first flashing
member is generally L-shaped.
39. The method of claim 38, wherein the provided second flashing
member is generally L-shaped.
40. The method of claim 37, wherein the formed continuous flange is
thermally bonded to the first or second continuous edge.
41. The method of claim 37, wherein the provided first and second
flashing members are polyolefin.
42. The method of claim 41, wherein the provided first and second
flashing members have a permeance of 0.3 perms or less.
43. The method of claim 37, wherein the formed flange extends over
a portion of the other of the second continuous edge or the first
continuous edge.
44. A method of creating a flashing device for doors, windows and
the like comprising: providing a first flashing member comprising a
first section including a first edge and a second section including
a second edge, the first and second edges disposed adjacently to
define a first continuous edge therealong; bending the first
section to a first angle with respect to the second section;
providing a second flashing member including a third and a fourth
edge, the third edge disposed at a second angle with respect to the
fourth edge, the second angle generally equal to the first angle,
the third and fourth edges adjacently disposed to define a second
continuous edge; heating at least one of the first continuous edge
or the second continuous edge; forming the at least one of the
first continuous edge or the second continuous edge that is heated
thereby providing a continuous flange along the at least one of the
first continuous edge or the second continuous edge; and affixing
the continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge to the other of the
second continuous edge or the first continuous edge.
45. The method of claim 44, wherein the provided first flashing
member is generally L-shaped.
46. The method of claim 45, wherein the provided second flashing
member is generally L-shaped.
47. The method of claim 44, wherein the formed continuous flange is
thermally bonded to the first or second continuous edge.
48. The method of claim 44, wherein the provided first and second
flashing members are polyolefin.
49. The method of claim 48, wherein the provided first and second
flashing members have a permeance of 0.3 perms or less.
50. The method of claim 44, wherein the formed flange extends over
a portion of the other of the second continuous edge or the first
continuous edge.
51. A method of creating a flashing device for doors, windows and
the like comprising: providing a first flashing member comprising a
first section including a first edge, and a second section
including a second edge, the first and second edges disposed
adjacently to define a first continuous edge therealong; bending
the first section to a first angle with respect to the second
section; providing a second flashing member comprising a third
section including a third edge, and a fourth section including a
fourth edge, the third and fourth edges disposed adjacently to
define a second continuous edge therealong, the third edge disposed
at a second angle with respect to the fourth edge; forming a
continuous flange along at least one of the first continuous edge
or the second continuous edge; and affixing the continuous flange
disposed along the at least one of the first continuous edge or the
second continuous edge to the other of the second continuous edge
or the first continuous edge.
52. The method of claim 51, wherein the provided first flashing
member is generally L-shaped.
53. The method of claim 52, wherein the provided second flashing
member is generally V-shaped.
54. The method of claim 51, wherein the provided second flashing
member is generally V-shaped.
55. The method of claim 51, wherein the provided continuous flange
is thermally bonded to the first or second continuous edge.
56. The method of claim 51, wherein the provided first and second
flashing members are polyolefin.
57. The method of claim 56, wherein the provided first and second
flashing members have a permeance of 0.3 perms or less.
58. The method of claim 51, wherein the formed flange extends over
a portion of the other of the second continuous edge or the first
continuous edge.
59. A method of creating a flashing device for doors, windows and
the like comprising: providing a first flashing member comprising a
first section including a first edge, and a second section
including a second edge, the first and second edges disposed
adjacently to define a first continuous edge therealong; bending
the first section to a first angle with respect to the second
section; providing a second flashing member including a third
section and a fourth section; cutting the third section and the
fourth section to define a V-shaped notch comprising a third edge
and a fourth edge, the third and fourth edges disposed adjacently
to define a second continuous edge therealong, the third edge
disposed at a second angle with respect to the fourth edge; heating
at least one of the first continuous edge or the second continuous
edge; forming at least one of the first continuous edge or the
second continuous edge that is heated thereby providing a
continuous flange along the at least one of the first continuous
edge or the second continuous edge; and affixing the continuous
flange disposed along the at least one of the first continuous edge
or the second continuous edge to the other of the second continuous
edge or the first continuous edge.
60. The method of claim 59, wherein the provided first flashing
member is generally L-shaped.
61. The method of claim 60, wherein the provided second flashing
member is generally V-shaped.
62. The method of claim 59, wherein the provided second flashing
member is generally V-shaped.
63. The method of claim 59, wherein the formed continuous flange is
thermally bonded to the first or second continuous edge.
64. The method of claim 59, wherein the provided first and second
flashing members are polyolefin.
65. The method of claim 64, wherein the provided first and second
flashing members have a permeance of 0.3 perms or less.
66. The method of claim 59, wherein the formed flange extends over
a portion of the other of the second continuous edge or the first
continuous edge.
67. A flashing device for doors, windows and the like comprising: a
first flashing member comprising a first section including a first
edge, a second section including a second edge and a third section
including a third edge, the first, second and third edges disposed
adjacently to define a first continuous edge therealong, the first
and second sections disposed at a first angle with respect to the
third section; a second flashing member including a fourth, a fifth
and a sixth edge, the fourth and fifth edges disposed at a second
angle with respect to the sixth edge, the second angle generally
equal to the first angle, the fourth, fifth and sixth edges
adjacently disposed to define a second continuous edge; and a
continuous flange disposed along at least one of the first
continuous edge or the second continuous edge; wherein the
continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous
edge.
68. The flashing device of claim 67, wherein the first flashing
member is generally U-shaped.
69. The flashing device of claim 68, wherein the second flashing
member is generally U-shaped.
70. The flashing device of claim 67, wherein the first continuous
flange is thermally bonded to the first or second continuous
edge.
71. The flashing device of claim 67, wherein the first and second
flashing members are polyolefin.
72. The flashing device of claim 71, wherein the first and second
flashing members have a permeance of 0.3 perms or less.
73. The flashing device of claim 67, wherein the flange extends
over a portion of the other of the second continuous edge or the
first continuous edge.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to a window or door
construction and more particularly to a flashing for sealing window
frames, door frames and the like.
[0002] "Flashing" is a term used to identify the methods and
devices, which are utilized to prevent water and air infiltration.
In recent years, numerous methods and devices have been made in an
effort to provide a solution to the problem of water and air
infiltration, particularly with regard to windows and doors in
either residential or commercial construction. Controlling water
and air intrusion is a serious concern and if not done properly may
result in damage to the construction. In addition, heat transfer
because of air infiltration is a significant factor in reducing the
energy efficiency of these buildings. Therefore, a need exists for
flashing methods and devices used therein, which can reduce or
eliminate the unwanted infiltration of water and/or air while
remaining relatively low in cost and easy to use.
[0003] In the past, one method for dealing with the potential for
water intrusion was to expect that some water will enter the
exterior wall openings and therefore, utilize methods and products
for flashing that minimize the amount of water/air infiltration
while simultaneously allowing water that has infiltrated the
construction to be removed by permeating through the flashing.
Water vapor permeance is a measure of the amount of water vapor
which can permeate or escape through a particular material. The
American Society for Testing and Materials (ASTM) has developed a
standard test method for water vapor transmission (E-96-00).
Generally speaking, a vapor permeance of less than about 0.3 perms
is considered a low permeance value, whereas a vapor permeance
greater than about 0.4 perms is considered a high permeance value.
Therefore, flashing products which provide for the permeation of
collected water will typically have a vapor permeance of 0.4 or
greater. Such products have been described in U.S. Patent
Application Publication No. U.S. 2001/0034984 A1.
[0004] In the alternative, a sealed approach has been developed
wherein the window or door frames are completely sealed from the
exterior environment in an effort to prevent the inward migration
of water and air from occurring in the first place. Such barriers
are available as Moistop E-Z Seal.RTM. from the Fortifiber
Corporation of Incline Village, Nev. The Moistop E-Z Seal.RTM. has
a vapor permeance of less than about 0.3 perms. Additional barriers
include Moistop.RTM. Flashing (<0.3 perms), Moistop neXT.TM.
Flashing (<0.05 perms) and Fortiflash (<0.08 perms), all
available from the Fortifiber Corporation.
[0005] The flashing methods and devices heretofore used require on
site fabrication and/or additional sealing steps to ensure that the
flashing device is properly sealed. These additional steps increase
the difficulty of installation as well as increasing costs.
Therefore, a need exists for a flashing product which is easy to
install, robust, and cost effective.
SUMMARY OF THE INVENTION
[0006] The aforementioned drawbacks and shortcomings of the prior
art are elegantly solved with the corner flashing system of the
present invention, which provides a window corner flashing device
which includes a first and a second member. The first member
includes a first section which is disposed adjacent to a second
section and is angled thereto. Each of the first section and second
section have a first edge and second edge, respectively, wherein
the first member includes a first continuous flange disposed along
the first and second edges of the first and second sections,
respectively. The second member includes a first section having a
third edge and a second section having a fourth edge. The second
member further includes a first continuous mating edge which is
disposed along the third and the fourth edge thereof. The first
member is affixed to the second member by having the first
continuous flange permanently affixed to the first continuous
mating edge.
[0007] Another aspect of the present invention is to provide a
window corner flashing device which includes a first and a second
flashing member. The first flashing member includes a first section
which further includes a first edge, and a second section including
a second edge. The first and second edges are disposed adjacently
to define a first continuous edge therealong. Further, the first
section is disposed at a first angle with respect to the second
section. The second flashing member includes a third and a fourth
edge, wherein the third edge is disposed at a second angle with
respect to the fourth edge. The second angle generally equals the
first angle and the third and fourth edges are adjacently disposed
to define a second continuous edge. A continuous flange is disposed
along at least one of the first continuous edge or the second
continuous edge, wherein the continuous flange disposed along the
at least one of the first continuous edge or the second continuous
edge is affixed to the other of the second continuous edge or the
first continuous edge.
[0008] Yet another aspect of the present invention is to provide a
window corner flashing device which includes a first and a second
flashing member. The first flashing member includes a first section
comprising a first edge and a second section comprising a second
edge. The first and second edges are disposed adjacently to define
a first continuous edge therealong, wherein the first section is
disposed generally orthogonal with respect to the second section.
The second flashing member includes a third and fourth edge,
wherein the third edge is disposed generally orthogonal to the
fourth edge. The third and fourth edges are adjacently disposed to
define a second continuous edge therealong. A continuous flange is
disposed along at least one of the first continuous edge or the
second continuous edge, wherein the continuous flange disposed
along the at least one of the first continuous edge or the second
continuous edge is affixed to the other of the second continuous
edge or the first continuous edge such that the first member may be
disposed generally orthogonally to the second member.
[0009] Still another aspect of the present invention is to provide
a window corner flashing device which includes a first and a second
member. The first flashing member includes a first section
comprising a first edge and a second section comprising a second
edge. The first and second edges are disposed adjacently to define
a first continuous edge therealong, wherein the first section is
disposed at a first angle with respect to the second section. The
second flashing member includes a third section comprising a third
edge and a fourth section comprising a fourth edge. The third and
fourth edges are disposed adjacently to define a second continuous
edge therealong, wherein the third edge is disposed at a second
angle with respect to the fourth edge. A continuous flange is
disposed along at least one of the first continuous edge or the
second continuous edge, wherein the continuous flange which is
disposed along the at least one of the first continuous edge or the
second continuous edge is affixed to the other of the second
continuous edge or the first continuous edge.
[0010] One aspect of the present invention is to provide a window
corner flashing device which includes a first and a second member.
The first flashing member includes a first section comprising a
first edge and a second section comprising a second edge. The first
and second edges are disposed adjacently to define a first
continuous edge therealong, wherein the first section is disposed
at a generally orthogonal angle with respect to the second section.
The second flashing member includes a third section comprising a
third edge, and a fourth section comprising a fourth edge, wherein
the third and fourth edges are disposed adjacently to define a
second continuous edge therealong. The third edge is disposed at a
generally orthogonal angle with respect to the fourth edge.
Further, a continuous flange is disposed along at least one of the
first continuous edge or the second continuous edge, wherein the
continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous edge
such that the first member may be disposed generally orthogonally
to the second member.
[0011] Another aspect of the present invention is to provide a
method for creating a window corner flashing device and includes
providing a first flashing member which includes a first section
comprising a first edge and a second section comprising a second
edge, wherein the first and second edges are disposed adjacently to
define a first continuous edge therealong. The first section is
then bent at a first angle with respect to the second section. A
second flashing member is provided which includes a third and a
fourth edge, wherein the third edge is disposed at a second angle
with respect to the fourth edge and wherein further the second
angle generally equals the first angle. The third and fourth edges
are adjacently disposed to define a second continuous edge. A
continuous flange is formed along at least one of the first
continuous edge or the second continuous edge and then affixed to
the other of the second continuous edge or the first continuous
edge.
[0012] Yet another aspect of the present invention is to provide a
method for creating a window corner flashing device and includes
providing a first flashing member including a first section
comprising a first edge and a second section comprising a second
edge. The first and second edges are disposed adjacently to define
a first continuous edge therealong and the first section is bent to
a first angle with respect to the second section. The second
flashing member is provided with and includes a third and a fourth
edge, wherein the third edge is disposed at a second angle with
respect to the fourth edge. The second angle is generally equal to
the first angle and the third and fourth edges are adjacently
disposed to define a second continuous edge. At least one of the
first continuous edge or the second continuous edge is heated and
at least one of the first continuous edge or the second continuous
edge is formed to provide a continuous flange along the at least
one of the first continuous edge or the second continuous edge. The
continuous flange disposed along the at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous
edge.
[0013] Still another aspect of the present invention is to provide
a method for creating a window corner flashing device and includes
providing a first flashing member including a first section
comprising a first edge and a second section comprising a second
edge. The first and second edges are disposed adjacently to define
a first continuous edge therealong. The first section is bent to a
first angle with respect to the second section. A second flashing
member is provided and includes a third section comprising a third
edge and a fourth section comprising a fourth edge, wherein the
third and fourth edges are disposed adjacently to define a second
continuous edge therealong. The third edge is disposed at a second
angle with respect to the fourth edge. A continuous flange is
formed along at least one of the first continuous edge or the
second continuous edge and affixed to the other of the second
continuous edge or the first continuous edge.
[0014] Yet another aspect of the present invention is to provide a
method for creating a window corner flashing device and includes
providing a first flashing member including a first section
comprising a first edge and a second section comprising a second
edge, wherein the first and second edges are disposed adjacently to
define a first continuous edge therealong. The first section is
bent to a first angle with respect to the second section. A second
flashing member is provided and includes a third section and a
fourth section. The third section and the fourth section are cut to
define a V-shaped notch comprising a third edge and a fourth edge,
wherein the third and fourth edges are disposed adjacently to
define a second continuous edge therealong. The third edge is
disposed at a second angle with respect to the fourth edge. At
least one of the first continuous edge or the second continuous
edge is heated and formed to provide a continuous flange along the
at least one of the first continuous edge or the second continuous
edge. The continuous flange disposed along the at least one of the
first continuous edge or the second continuous edge is affixed to
the other of the second continuous edge or the first continuous
edge.
[0015] Yet still another aspect of the present invention is to
provide a flashing device and includes a first flashing member
comprising a first section including a first edge, a second section
including a second edge, and a third section including a third
edge. The first, second and third edges are disposed adjacently to
define a first continuous edge therealong, and the first and second
sections are disposed at a first angle with respect to the third
section. A second flashing member includes a fourth, a fifth and a
sixth edge, wherein the fourth and fifth edges are disposed at a
second angle with respect to the sixth edge. The second angle is
generally equal to the first angle. The fourth, fifth and sixth
edges are adjacently disposed to define a second continuous edge. A
continuous flange is disposed along at least one of the first
continuous edge or the second continuous edge, wherein the
continuous flange disposed along at least one of the first
continuous edge or the second continuous edge is affixed to the
other of the second continuous edge or the first continuous
edge.
[0016] One aspect of the present invention is to provide a flashing
device which includes a flashing member comprising a first polymer
layer and a second adhesive layer. The second adhesive layer
includes a non-adhering portion surrounded by the adhesive portion
on at least three sides thereof and the non-adhering portion
extends to at least one edge of the flashing member.
[0017] Yet another aspect of the present invention is to provide a
method for creating a flashing device and includes providing a
flashing member which comprises a first polymer layer and a second
adhesive layer. The second adhesive layer includes a non-adhering
portion surrounded by the adhesive portion on at least three sides
thereof. The non-adhering portion is disposed at least partially
along one edge of the flashing member. At least part of the
adhesive layer is affixed to a bottom outside flange of a window
frame or a door frame and to an outside bottom face of a
construction below a building structural aperture wherein the
window frame or door frame is installed. At least part of the
non-adhering portion is disposed adjacent to the outside flange of
the window frame or the door frame, and at least part of the
non-adhering portion which is disposed along the at least one edge
of the flashing member is disposed below the flange of the window
frame, door frame or the like, wherein water that has collected
within a window frame, door frame or the like drains through the
non-adhering portion of the flashing member.
[0018] Still another aspect of the present invention is to provide
a method for flashing door frames, window frames or the like,
wherein the frames have an outside bottom flange therealong and
includes providing a flashing member comprising a polymer sheet
including a first and a second side, a top and a bottom edge and
two opposite sides. A sealant is applied to the second side of the
flashing member to segment the second side such that the second
side includes at least one non-sealed section surrounded by sealant
on at least three sides thereof, wherein the non-sealed section is
disposed at least partially along the bottom edge of the flashing
member. The top edge of the flashing member is affixed to the
outside flange of the door frame, window frame or the like, wherein
water that has collected within a window frame or a door frame
drains through the non-sealed section of the flashing member.
[0019] Yet another aspect of the present invention is to provide a
method of flashing doors, windows and the like wherein the doors,
windows and the like include at least a flange along a bottom edge
thereof and includes providing a sealant and partially sealing with
the sealant at least the bottom flange of the door or window to an
outside bottom perimeter of a building construction face, below a
construction aperture, wherein the portion of the flange which is
not sealed defines at least one opening having two opposite sides.
A flashing member comprising a top edge, a bottom edge and opposite
side edges is provided and a sealant is applied to the flashing
member along the top edge and the opposite side edges. The top edge
of the flashing member is attached to an outside surface of the
bottom flange. The flashing member is disposed over the opening and
extends laterally beyond the opposite two sides of the opening, and
vertically below the opening, thereby sealing the top edge and
opposite side edges to the outside surface of the flange and the
construction face, respectively. The bottom edge extends vertically
below the opening a sufficient distance so as to prevent water from
entering the opening, wherein the sufficient distance is determined
by the wind speed the construction may face and is calculated as
follows: [Wind speed (miles/hour)].sup.2.times.0.00256 Velocity
Pressure (pounds/ft.sup.2), whereby Velocity Pressure
(pounds/ft.sup.2).times.0.192=Distance of vertical extension of
flashing member (inches of water). The result, in inches of water,
determines the amount of the vertical extension (in inches) the
flashing member extends below the opening.
[0020] Still yet another aspect of the present invention is a
flashing device for doors, windows and the like which is installed
in a construction aperture, wherein the doors, windows and the like
include at least a flange along a bottom edge thereof. The flange
is disposed along a bottom perimeter of the construction aperture
and extends along at least a portion of a face of the construction.
The flashing device includes a flashing member further including a
top edge, a bottom edge, opposite side edges and a first side. A
sealant is disposed on the first side of the flashing member, at
least interiorly of said top edge and opposite side edges, to
define a sealant-free channel thereon, wherein the channel is
surrounded by sealant on at least three sides thereof. The channel
extends to the bottom edge of the flashing member. The top edge of
the flashing member is disposed over the bottom flange of the door
or window and the flashing member extends downward on the outside
face of the construction, wherein the channel extends from at least
an edge of the flange, vertically downward below the construction
aperture, at least 2 inches.
[0021] Other objects, advantages and features of the invention will
become apparent upon a consideration of the following detailed
description, when taken in conjunction with the accompanying
drawings. The above brief description sets forth rather broadly the
more important features of the present disclosure so that the
detailed description that follows may be better understood, and so
that the present contributions to the art may be better
appreciated. There are, of course, additional features of the
disclosure that will be described hereinafter which will form the
subject matter of the claims appended hereto.
[0022] In this respect, before explaining the preferred embodiment
of the disclosure in detail, it is to be understood that the
disclosure is not limited in its application to the details of the
construction and the arrangements set forth in the following
description or illustrated in the drawings. The flashing system of
the present disclosure is capable of other embodiments and of being
practiced and carried out in various ways. Also, it is to be
understood that the phraseology and terminology employed herein are
for description and not limitation. Where specific dimensional and
material specifications have been included or omitted from the
specification or the claims, or both, it is to be understood that
the same are not to be incorporated into the appended claims.
[0023] As such, those skilled in the art will appreciate that the
conception, upon which the disclosure is based, may readily be used
as a basis for designing other structures, methods and systems for
carrying out the several purposes of the present invention. It is
important, therefore, that the claims are regarded as including
such equivalent constructions as far as they do not depart from the
spirit and scope of the present invention.
[0024] Further, the purpose of the Abstract is to enable the U.S.
Patent and Trademark Office and the public generally, and
especially the scientists, engineers and practitioners in the art
who are not familiar with the patent or legal terms of phraseology,
to learn quickly from a cursory inspection the nature and essence
of the technical disclosure of the application. Accordingly, the
Abstract is intended to define neither the invention nor the
application, which is only measured by the claims, nor is it
intended to be limiting as to the scope of the invention in any
way.
[0025] These and other objects, along with the various features and
structures that characterize the invention, are pointed out with
particularity in the claims annexed to and forming a part of this
disclosure. For a better understanding of the flashing system of
the present disclosure, its advantages and the specific objects
attained by its uses, reference should be had to the accompanying
drawings and descriptive manner in which there are illustrated and
described the preferred embodiments of the invention.
[0026] Therefore, while embodiments of the corner flashing system
are herein illustrated and described, it is to be appreciated that
various changes, rearrangements and modifications may be made
therein, without departing from the scope of the invention as
defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of the corner flashing device
according to a first embodiment of the present invention, in a
typical construction frame;
[0028] FIG. 2 is a perspective view of the corner flashing device
of FIG. 1;
[0029] FIG. 3 is an exploded view of the corner flashing device of
FIG. 2;
[0030] FIG. 4 is an exploded view of a second embodiment of a
corner flashing device;
[0031] FIG. 5 is a fragmentary perspective view of a third
embodiment of a corner flashing device in a typical construction
frame;
[0032] FIG. 6 is an exploded perspective view of the corner
flashing device of FIG. 5;
[0033] FIG. 7 is a perspective view of a machine used to fabricate
the corner flashing device of FIG. 5;
[0034] FIG. 8 is a partial perspective view of a folding station
and a plow station portion of the machine of FIG. 7;
[0035] FIG. 9 is an front view of the folding station and plow
station portion of FIG. 8;
[0036] FIG. 10 is a perspective view of a first member and a second
member of the corner flashing device of FIG. 5 prior to a folding
and sealing step;
[0037] FIG. 11 is a perspective view of the first member and the
second member of FIG. 10 during the folding and sealing step;
[0038] FIG. 12 is a perspective view of the first member and the
second member of FIG. 10 after the folding and sealing step;
[0039] FIG. 13 is a front view of a valve flashing device according
to a preferred embodiment of the present invention, in a typical
construction frame;
[0040] FIG. 14 is a bottom view of the flashing device of FIG.
13;
[0041] FIG. 15 is a partial cross-sectional view of the flashing
device of FIG. 14 taken along line XV-XV of FIG. 14;
[0042] FIG. 16 is a partial cross-sectional view through line
XVI-XVI of the construction of FIG. 13;
[0043] FIG. 17 is a perspective view of a pair of corner flashing
devices incorporated into a sill pan flashing member according to
yet another embodiment of the present invention; and
[0044] FIG. 18 is an exploded perspective view of the flashing
device of FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] The best mode for carrying out the invention is presented in
terms of the preferred embodiment, wherein similar reference
characters designate corresponding features throughout the several
figures of the drawings.
[0046] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the invention
as oriented in FIG. 1. However, it is to be understood that the
invention may assume various alternative orientations, except where
expressly specified to the contrary. It is also to be understood
that the specific devices and processes illustrated in the attached
drawings, and described in following specification, are simply
exemplary embodiments. Hence, specific dimensions and other
physical characteristics relating to the embodiments disclosed
herein are not to be construed as limiting, unless expressly stated
otherwise.
[0047] Referring now to the drawings, particularly FIG. 1, there is
shown in perspective view a first embodiment of the inventive
corner flashing device in use on an exemplary window frame
construction. The corner flashing device 2 consists primarily of a
first sill member 10 and a second face member 30 engaged along a
continuous flange 22 to form the corner flashing device as
illustrated in FIG. 2.
[0048] First sill member 10 includes a first section 12 comprising
a first edge 13 and a second section 16 comprising a second edge
17. With respect to FIG. 3, first and second sections 12 and 16,
respectively, are generally rectangular in shape wherein the first
and second edges 13 and 17, respectively, are disposed adjacent to
one another to define a first continuous edge 20 therealong. First
and second edges 13 and 17 are disposed with respect to one another
at an angle .theta..sub.1 which equals the angle of the
corresponding window frame structure wherein the corner flashing
device is to be used. For example, when flashing a standard square
window opening having four intersections which meet orthogonally,
first section 12 will be disposed orthogonally to second section 16
to create an L-shaped sill member 10. However, this angle does not
have to be orthogonal and sections 12 and 16 may be disposed at
different angles to meet the specific requirements of the window
construction. Further, first and second sections 12 and 16 need not
be rectangular in shape but may take any shape as the specific
requirements dictate. For example, first and second sections 12 and
16 may be the same length, different lengths and/or different
geometries according to the specific requirements of the frame
construction.
[0049] As described above, first and second sections 12 and 16
together define first sill member 10. Although first sill member 10
may be fabricated from two or more individual pieces, the preferred
embodiment utilizes a single piece of material which is bent or
angled to angle .theta..sub.1 thereby forming a radius R along the
vertex thereof. In the preferred embodiment, this radius is about
1/8 of an inch but may range in size to accommodate the specific
requirements of the construction to be flashed. Sill member 10 also
includes continuous edge 20 disposed along a front edge of sections
12 and 16, from which a first continuous flange 22 is formed as
discussed below. First continuous flange 22 is formed from first
member 10 by bending, creasing or otherwise folding over a
continuous portion of edge 20 in a direction which extends away
from a top surface 21 towards the opposite side thereof.
[0050] Sill member 10 may be fabricated from numerous materials.
Generally, a flexible material is used such that sill member 10 is
capable of conforming to and flashing the rough opening of a door,
window, or the like. Such materials are commonly known within the
art and may include, but are not limited to, polymer sheeting or
film. The thickness of the sheeting or film may also vary according
to the specific requirements of the construction. However, a
preferred range is from about 2 mils (0.002 inches) to about 125
mils (0.125 inches), more preferably from about 3.5 mils (0.0035
inches) to about 40 mils (0.040 inches) and most preferably from
about 5 mils (0.005 inches) to about 20 mils (0.020 inches). In a
preferred embodiment, a virtually non-permeable high strength
polyolefin sheet with a permeability of 0.3 perms or less is used
and has an approximate thickness of 12 mils (0.012 inches). The
method of fabricating sill member 10 is discussed hereinafter.
[0051] With respect to FIG. 3, second face member 30 includes a
first section 32 comprising a third edge 33 and a second section 36
comprising a fourth edge 37. First and second sections 32 and 36,
respectively, are generally rectangular in shape and the third and
fourth edges 33 and 37, respectively, are disposed adjacent to one
another to define a first continuous mating edge 40 therealong.
Third and fourth edges 33 and 37 are disposed with respect to one
another at an angle .theta..sub.2. Angle .theta..sub.2 generally
equals angle .theta..sub.1 of corresponding sill member 10. For
example, when flashing a standard square window opening as
discussed above, first section 32 and second section 36 will be
planarly disposed creating an orthogonal angle .theta..sub.2,
thereby creating an L-shaped face member 30. However, this angle
does not have to be orthogonal and sections 32 and 36 may be
disposed at different angles to meet the specific requirements of
the window construction. Further, first and second sections 32 and
36 need not be rectangular in shape but may take any shape as the
specific requirements dictate. For example, first and second
sections 12 and 16 may be the same length, different lengths and/or
different geometries according to the specific requirements of the
frame construction. Further yet, although face member 30 may be
fabricated from two or more individual sections, the preferred
embodiment utilizes a single piece of material which is fabricated
having the specified angle .theta..sub.2. By having angle
.theta..sub.1 and .theta..sub.2 generally correspond to each other,
continuous edge 40 of face member 30 may be affixed to continuous
flange 22 of sill member 10 to form flashing device 2 as described
hereinafter. As described above, angle .theta..sub.1 and
.theta..sub.2 need only "generally correspond" in angle. The term
"generally" as used herein means that the corresponding angles need
not be exact, but are sufficiently close such that the two angled
parts, and more particularly the angled flange and corresponding
edge, may be affixed to one another without any openings or gaps
therebetween. The amount of variance depends on, among other
things, the amount of overlap, the length of the edge and
manufacturing tolerances.
[0052] The reference numeral 2A (FIG. 4) generally designates
another embodiment of the present invention having a continuous
flange 42. Since window flashing device 2A is similar to the
previously described window flashing device 2, similar parts
appearing in FIGS. 1-3 and FIG. 4, respectively, are represented by
the same, corresponding reference numeral, except for the suffix
"A" in the numerals of the latter. In window flashing device 2A,
face member 30A includes a second continuous flange 42 disposed
along continuous edge 40A for interconnection with continuous
flange 22A of sill member 10A. Second continuous flange 42 may be
formed from second member 30A by bending, creasing or otherwise
folding over a portion of the material along continuous edge 40A in
a direction which extends away from a top surface 41A. In an
alternative embodiment, second member 30A may solely include a
flange for attachment to continuous edge 20A of first member
10A.
[0053] Face members 30 and 30A may be fabricated from numerous
materials. As with sill member 10, a flexible material is used such
that face members 30 and 30A are capable of conforming to and
flashing the rough opening of a door, window, or the like. Such
materials are commonly known within the art and may include, but
are not limited to, polymer sheeting or film. Although face members
30 and 30A may be fabricated from a material which is different
from the material of sill member 10, in the preferred embodiment
the same virtually non-permeable high strength polyolefin sheet
with a permeability of 0.3 perms or less and a thickness of 12 mils
(0.012 inches) is used. The thickness of the sheeting or film may
also vary according to the specific requirements of the
construction. However, a preferred range is from about 2 mils
(0.002 inches) to about 125 mils (0.125 inches), more preferably
from about 3.5 mils (0.0035 inches) to about 40 mils (0.040 inches)
and most preferably from about 5 mils (0.005 inches) to about 20
mils (0.020 inches). The method of fabricating face members 30 and
30A is discussed hereinafter.
[0054] The reference numeral 2B (FIG. 5) generally designates
another embodiment of the present invention having a V-shaped
member 30B. Since window flashing device 2B is similar to the
previously described window flashing device 2, similar parts
appearing in FIGS. 1-3 and FIGS. 5-6, respectively, are represented
by the same, corresponding reference numeral, except for the suffix
"B" in the numerals of the latter. In window flashing device 2B a
first member 10B and a second member 30B are engaged along a
continuous flange 22B of first member 10B (FIG. 6).
[0055] First member 10B includes a first section 12B comprising a
first edge 13B and a second section 16B comprising a second edge
17B. With respect to FIG. 6, first and second sections 12B and 16B,
respectively, are generally rectangular in shape and first and
second edges 13B and 17B, respectively, are disposed adjacent to
one another to define a first continuous edge 20B therealong. First
and second edges 13B and 17B are disposed with respect to one
another at an angle .theta..sub.1B which equals the angle of the
corresponding window frame structure wherein the corner flashing
device is to be used. For example, when flashing a standard square
window opening having four intersections, top and bottom sills and
two side jambs, .theta..sub.1B will generally be 90.degree.
enabling section 16B to be positioned against the sill of the
construction frame and section 12B to be positioned against the
side jamb of the construction frame. Of course, if the jamb and
face of the construction were at an angle other than 90.degree.,
.theta..sub.1B could be made to accommodate these custom angles as
the specific requirements dictate. Further, first and second
sections 12B and 16B need not be rectangular in shape but may take
any shape as the specific requirements dictate. Further yet,
although sill member 10B may be fabricated from two or more
individual pieces, the preferred embodiment utilizes a single piece
of material which is bent or angled to angle .theta..sub.1B,
thereby forming a radius R along the vertex thereof. In the
preferred embodiment, this radius is about 1/8 of an inch but may
range in size to accommodate the specific requirements of the
construction to be flashed. First member 10B includes continuous
edge 20B disposed along an edge of sections 12B and 16B, wherein a
first continuous flange 22B is disposed. First continuous flange
22B is formed from first member 10B by bending, creasing or
otherwise folding continuous edge 20B in a direction which extends
away from a top surface 21B.
[0056] Second member 30B includes a generally trapezoidal first
section 32B comprising third edge 33B and a generally trapezoidal
second section 36B comprising fourth edge 37B. Third and fourth
edge 33B and 37B are disposed adjacent one another to form a
generally V-shaped continuous edge 40B having an angle
.theta..sub.2B. Second member 30B also includes bottom V-shaped
edge section 34 having an angle .theta..sub.2B. Angle
.theta..sub.2B is generally equal to angle .theta..sub.1B and in
the case of a standard construction frame, this angle would be
generally 90.degree. as illustrated by FIG. 5. Of course, angle
.theta..sub.2B may be varied to meet specific requirements. As
described above with respect to the other embodiments, continuous
V-shaped edge 40B, disposed along the upper edges of second member
30B, is interconnected with continuous flange 22B thereby forming
window flashing device 2B.
[0057] The incorporation of V-shaped edge sections 40B and 34B to
second member 30B allQws window flashing device 2B to be fabricated
with significantly reduced waste material. In the preferred
embodiment this can be attributed to V-shaped continuous edge 40B
of second member 30B having generally the same shape and angle as
angled flange 22B. By having the same general shape, the material
does not require cutting or trimming, either before or after the
interconnection between first member 10B and second member 30B and
therefore, waste material is reduced. Further, V-shaped edge 34 is
also cut or otherwise shaped into the same general V-shape as
opposite edge 40B. These opposite but similarly shaped end sections
allow the part to be made, when using a continuous sheet, roll or
other continuous process or material, from a single step or cut in
the process. This is accomplished because as V-shaped edge section
34 is being cut, the remaining cut edge on the material is shaped
as, and can therefore be used as, V-shaped edge section 40B of the
subsequent part. Therefore, waste material is reduced, process
steps are eliminated and productivity is increased by this unique
V-shaped edge design.
[0058] As best illustrated by FIG. 5, second member 30B of window
flashing device 2B is typically disposed on the construction frame
such that member 30B is retained on or flashes the face of the
construction frame, while member 10B flashes the sill and side
joint of the construction. However, this is merely the preferred
embodiment and flashing device 2B, and more particularly first
member 10B and second member 30B, may be reversed, interchanged or
otherwise disposed in numerous other configurations. In addition,
window flashing device 2B may be fabricated from various materials
and from various geometries as described above with regard to the
previous embodiments.
[0059] The method of fabricating the various described embodiments
is illustrated in FIGS. 7-12. Although reference will be made
specifically to window flashing device 2B, the various other
embodiments may be fabricated through similar techniques, devices
and principles. With respect to FIG. 7, a fabrication and assembly
machine 100 is shown and includes four primary stations comprising
marking stations 108, cutting stations 110, folding/sealing
stations 120 and plow stations 130, which simultaneously fabricate
a pair of flashing devices 2B. A fifth gripping station 109 is also
included to aid in the feeding of roll material 102 as described in
more detail below. The overall configuration of the machine is as
follows: a continuous roll of material 101 for fabricating a pair
of first members 10B, and a pair of continuous rolls of material
102 for fabricating a pair of second members 30B, are disposed
upstream of machine 100. The term upstream is meant to signify that
the material is disposed before the machine in terms of the process
sequence and does not necessarily signify the physical location.
The material of continuous rolls 101 and 102 is routed, moved or
otherwise transferred to their respective stations through systems
and methods which are well known in the art. Further, machine 100
accomplishes many of the movements and actions herein described,
simultaneously, as such, the system does not necessarily have a
linear sequence of events. Therefore, the system will be described
by reference to the various stations and the actions performed
therein. It is also to be understood that various modifications may
be made to the machine, its sequences, methods, orientations and
the like without departing from the inventive concept and that the
description contained below is merely a preferred embodiment and
hence, not meant to be limiting unless stated otherwise. Further
yet, when specific reference is made to first and second members
10B and 30B, their orientation, step sequences, processes and the
like, it is to be understood that members 10B and 30B may used
interchangeably.
[0060] Marking station 108 is the first station with respect to
roll material 102 and transfers, embosses or otherwise leaves an
image on a portion of roll material 102. For example, a logo can be
heat stamped at this station. Roll material 102 is then fed to
cutting station 110 (described below). At this station roll
material 102 is cut into the desired shape using cutting head 112.
In the preferred embodiment, a V-shaped edge having angle
.theta..sub.2B is cut. In this manner, a single cutting action
creates the trailing edge 34 of second member 30B, which has
forward edge 40B disposed within station 120, as well as creating
leading edge 40B of the next second member 30B in the continuous
process. Hence, a single cut creates edge 34B of the part in
process and edge 40B of the part which is next in process.
[0061] Gripping station 109 and folding station 120 move up and
down, along shafts 114, in unison, thereby assisting with the
feeding of roll material 102 as follows. After cutting station 110
cuts roll material 102, by pressing cutting head 112 against a
plate 111, gripping station 109 and folding station 120 descend
simultaneously on shafts 114, and arrive at the position shown in
FIG. 7. Gripping station 109, which is positioned above cutting
station 110, in conjunction with folding station 120, which is
positioned below cutting station 110, then activate or grip roll
material 102, whereby gripping station 109 grips the uncut roll
material 102 above cutting station 110 and folding station 120
grips the cut roll material 102 below station 110.
[0062] Either subsequent to or concurrent with the above sequence,
roll material 101 is moved forward thereby removing device 2B from
station 120 and providing new material to station 120 for creating
first member 10B by positioning material 101 underneath angle plate
104. Angle plate 104 is angled to the desired angle .theta.1B. With
roll material 101 and 102 positioned within station 120, the
folding and sealing operations take place. As best illustrated by
FIGS. 8-9, roll material 101 is disposed such that edge 20B extends
beyond angle plate 104. This exposed edge defines flange 22B. In
the preferred embodiment, edge 20B extends beyond angle plate 104
approximately 0.25 inches.
[0063] Once both members 10B and 30B, and more specifically flange
22B and edge 40B are positioned within folding/sealing station 120,
a heater 122 is used to pre-heat flange 22B. Heater 122 will
pre-heat flange 22B to a temperature necessary to foster pliability
in flange 22B. In a preferred embodiment, this temperature is
approximately 250 degrees Fahrenheit. The pre-heat treatment makes
it possible for the material of flange 22B, more particularly the
vertex 23 thereof, to stretch during the subsequent folding
operation described below (FIGS. 10-12). After preheating,
folding/sealing station 120 retracts, allowing plow station 130
which includes a V-shaped head 132 to travel upward (FIG. 9),
wherein head 132 traverses over flange material 22B bending it over
and forming the flange over edge 40B of roll material 102. The
illustrative folding of flange 22B and formation over edge 40B is
illustrated by FIGS. 10-12.
[0064] Positioned in or near plate 123 of station 120 is a heating
device (not shown) that will then heat flange 22B and edge 40B,
sealing flange 22B to edge 40B, thereby forming a continuous double
layer joint. Although numerous methods can be used to join, affix
or weld these edges together, in the preferred embodiment, heat
sealing is advantageously utilized. In conjunction with the closing
of folding/sealing station 120 to retain roll material 102, as well
as apply pressure when flange 22B and edge 40B are affixed, cutting
station 110 also closes to cut the opposite end of edge 34B of
second member 30B as described previously. Stations 109 and 120
then move vertically upward and return to their original positions,
and the process repeats. Various other operations, such as opening
folding/sealing station 120, returning plow station 130, cutting
roll material 101 and the like, which contribute to the fabrication
of window flashing 2B, occur downstream of these operations and are
not critical to the inventive concept. The resultant double layered
seal provides increased strength creating a durable sealed edge
which provides a continuous seal without the notches or various
other openings exhibited by the prior art devices which may either
initially, or over time, destroy the sealing capabilities of the
flashing device.
[0065] The reference numeral 2C (FIG. 13) generally designates
another embodiment of the present invention which includes a
one-way valve member 50. Since window flashing device 2C is similar
to the previously described window flashing device 2B, similar
parts appearing in FIGS. 5-6 and FIGS. 13-16, respectively, are
represented by the same, corresponding reference numeral, except
for the suffix "C" in the numerals of the latter. In window
flashing device 2C a valve member 50 is utilized in addition to
flashing devices 2C which are installed in at least the lower two
corners of the construction frame, between the side jambs and the
lower sill.
[0066] As illustrated in FIGS. 13-16, the valve member 50 is
generally a sheet of polymer 51 which is adhered or otherwise
sealed to the outside lower flange of a window frame, door frame,
or the like. With respect to FIG. 14, valve member 50 includes a
sealed area 52 which surrounds a non-sealed area 54 on three sides
thereof, whereby non-sealed area 54 extends to at least one edge 56
of valve member 50.
[0067] The installed valve member 50 is illustrated in FIGS. 13 and
16. Prior to the installation of valve member 50, window corner
flashing devices 2C are installed in the construction frame. Each
corner of the construction frame will typically include a corner
flashing device 2C. A sill pan 60 is then installed and sealed over
the corner flashing devices 2C disposed in the lower two corners of
the construction frame and the corresponding sill. The sill pan 60
is installed such that it adheres, seals or covers the entire sill
and extends downward, on the front outside of the sill, to prevent
water from entering the construction. A window, door, or the like
5, which typically includes a flange 61 surrounding the frame, is
then installed and completely sealed on the top and sides thereof.
This is typically done by utilizing a caulk or other sealant on the
frame between the frame of the window, door, or the like 5 and the
structural aperture or construction opening. The lower sill area of
the frame is then partially sealed to leave at least one small
opening or gap in the sealant from which water may traverse
therethrough.
[0068] The installation of valve member 50 is achieved by adhering
or otherwise sealing the rear adhesive portion of valve member 50,
along top edge 55, to the lower outside flanged member 61 of the
installed window frame, door frame, or the like 5. Valve member 50
is positioned along the flange such that it resides over and covers
the small opening or gap in the sealant of the sill while at least
a portion of non-sealed area 54 either resides on or is adjacent to
the lower edge of flange 61. As best illustrated in FIG. 16, valve
member 50 and more particularly non-sealed area 54 extends downward
from flange 61 along the outside face of the construction. In the
preferred embodiment two sealant gaps are used on the sill, each
approximately one inch wide, and a pair of valve members 50 are
used and include approximately a two inch wide non-sealed area
which extends approximately three inches down the front face of the
construction. In another preferred embodiment, a single gap is used
an disposed centrally with respect to the bottom window flange and
a single valve member 50 is utilized.
[0069] The installed valve member 50 inventively creates a one-way
valve member which, while not allowing water into the construction
from the outside, allows water that has entered the construction to
be drained therefrom as illustrated by the arrows in FIG. 16. This
one-way valve design is accomplished through the use of non sealed
area 54 of valve member 50.
[0070] When a sill pan 60 is used in typical flashing
installations, the sill pan 60 is affixed or sealed to the sill of
the construction providing what is to be a barrier between the
window, door or the like 5, and the corresponding construction.
However, the seal, which is typically achieved by caulking,
sealant, adhesives and the like, generally does not achieve 100%
wet out or adhesion along the entire perimeter of the window or
door and thus, un-sealed areas or channels are created which can
provide paths from which water can enter into the construction.
Additionally, water may enter the construction through various
other routes such as leaks in the window or door. For example,
through separated frame components, broken flanges, glass/frame
interfaces as well as gaps in the flange perimeter sealant. The
water typically enters the construction due to a pressure
differential that is created between the inside and outside of the
completed construction. This pressure difference can be created,
for example, by wind pressure. Advantageously, these channels allow
the water which has collected to drain once the higher outside
pressure has been removed. The primary purpose of sealing members
50 is to allow for necessary drainage in the sill pan system while
at the same time preventing water ingress through the same opening
by acting as a one-way valve to eliminate or greatly reduce the
pressure differential that could cause water to migrate inward to
the interior side of the wall.
[0071] It has been inventively discovered that when valve member 50
is installed as described above, water is not allowed into the
construction, yet any water that has entered the construction
through other areas, for example through a window leak, may be
drained through non sealed area 54. This one-way-valve design is
accomplished by providing valve member 50 with the non-sealed area
54 which is vertically disposed to provided a channel 54, wherein
any water that has collected on the inside of the construction may
drain to the outside through the sealant gap and down channel 54.
However, by utilizing this vertical orientation of valve member 50,
for water to enter the construction it must flow vertically upward,
underneath valve member 50 and into non-sealed area 54. The amount
of pressure that it takes for water to travel vertically upward
through the channel formed by non-sealed area 54 depends upon the
amount of vertical overhang, or vertical dimension of non-sealed
area 54. The required vertical dimension, in inches, must be a
sufficient dimension so as to prevent water from migrating up the
non-sealed area and into the opening by the aforementioned pressure
of difference. Therefore, the vertical dimension must exceed the
pressure difference between the inside of construction and the
outside thereof at the opening. The sufficient distance can be
calculated by determining the maximum wind speed the construction
will face as described below. The required vertical dimensions, in
inches, must exceed the gap opening expressed in units of inches of
water. The velocity pressure can be derived from wind speed by
utilizing the following equations:
Velocity pressure (pounds/ft.sup.2)=0.00256.times.[Wind Speed
(miles per hour)].sup.2; 1)
Distance=inches of water=0.192.times.velocity pressure
(pounds/ft.sup.2); 2)
[0072] For example, at a wind speed of 75 MPH: Velocity
Pressure=0.0.00256.times.[75].sup.2=14.4 pounds/ft.sup.2 and
Vertical Distance=0.192.times.14.4=2.76 inches of water. Therefore,
at least a 2.76 inch vertical overhang is required to withstand
this wind speed. It has been demonstrated that when using a 3.0
inch vertical overhang and a 2.0 inch wide non-sealed area, a
pressure of 15.0 pounds-per-square-foot can be sustained without
allowing water to travel into the construction. This equates to a
wind speed of over 79 miles-per-hour. Therefore an effective
one-way-valve flashing design has been developed which restricts
water from entering the construction while allowing any water that
has entered to be drained away to the outside.
[0073] Valve member 50 may be fabricated from numerous materials.
Generally, a flexible material is used such that valve member 50 is
capable of conforming to and flashing the construction opening of a
window sill, door sill, or the like. Such materials are commonly
known within the art and may include, but are not limited to,
polymer sheeting and films. The thickness of the sheeting or film
may also vary according to the specific requirements of the
construction. However, a preferred range is from about 2 mils
(0.002 inches) to about 125 mils (0.125 inches), more preferably
from about 3.5 mils (0.0035 inches) to about 40 mils (0.040 inches)
and most preferably from about 5 mils (0.005 inches) to about 20
mils (0.020 inches). In a preferred embodiment a virtually
non-permeable high strength polyolefin sheet with a permeability of
0.3 perms or less is used having an approximate thickness of 12
mils (0.012 inches). The adhesive of valve member 50 may also be
fabricated from numerous materials. Generally, a pressure sensitive
adhesive is preferred. For example, a modified asphalt or butyl
rubber based adhesive may be used. Such a material is available as
Moistop E-Z Seal.RTM. as mentioned previously. Further, the Moistop
E-Z Seal.RTM. includes an adhesive backed side that can be used to
create sealed areas 52 while non sealed area 54 can be created by
leaving a portion of the release liner, attached to protect the
adhesive layer, thereon. Although a non permeable material has been
discussed with particularity, a permeable polymer could also be
used for valve member 50 to provide additional avenues of escape
for collected water.
[0074] Although an adhesive back material has been exemplarily
described, the one-way valve concept can also be achieved with
other materials and sealing methods. For example, separately
applying caulking or sealant to create flashing member 50. In this
embodiment, the caulking or sealant is applied, on site, to a
second face of a polymer sheet or film. This may be accomplished by
completely covering an area 52 with a sealant and leaving area 54
unsealed or free of the sealant, or by providing a caulking bead or
seam along a perimeter of non-sealed area 54, thereby creating
non-sealed area 54 by segmenting flashing member 50 into the sealed
and non-sealed areas as illustrated by FIG. 14.
[0075] Another embodiment of the one-way valve design can be
fabricated by:
[0076] 1) initially sealing a door frame, window frame or the like
on all sides except for a portion of the bottom of the frame,
wherein the portion of the frame which is not sealed defines an
opening having two opposite sides;
[0077] 2) utilizing a polymer flashing member, with no adhesive or
sealant thereon, the flashing member comprising a top edge, a
bottom edge and opposite side edges;
[0078] 3) sealingly attaching the top edge of the flashing member
to a bottom outside flange of a window frame, door frame or the
like, over the opening, whereby the flashing member extends
laterally beyond the opposite two sides of the opening. The seal
between the top edge and the outside flange may be, for example, a
bead of caulking;
[0079] 4) sealingly attaching the flashing member between each of
the opposite side edges to a face of a construction aperture, below
a window frame, door frame or the like. The seal between the
opposite side edges may be, for example, a bead of caulking;
and
[0080] 5) extending the bottom edge below the opening from about 1
inch, more preferably about 2 inches and most preferably about 3
inches.
[0081] In this manner, a polymer sheet can be used to create a one
way valve without the necessity of additional sealant being
manufactured thereon. This fabrication allows water that has
collected within the construction to drain through the flashing
member, while keeping water from entering the construction in the
first place.
[0082] The reference numeral 70 (FIG. 17) generally designates
another embodiment of the present invention which includes an
integral sill pan member 60D. Since window flashing device 2D is
similar to the previously described window flashing device 2B,
similar parts appearing in FIGS. 5-6 and FIG. 17, respectively, are
represented by the same, corresponding reference numeral, except
for the suffix "D" in the numerals of the latter. In window
flashing device 70 a pair of corner flashing members 2D are
integrally fabricated to include a sill pan flashing member
60D.
[0083] With reference to FIG. 17, flashing device 70 includes a
first member 10D and a second member 30D integrally attached by a
continuous flange 22D disposed along one or both continuous edges
20D and 37D of first and second members 10D and 30D, respectively.
In the preferred embodiment, flange 22D is disposed along first
continuous edge 20D of first member 10D. Flange 2D may be formed
from first member 10D by bending, creasing or otherwise folding
over a portion of the material along continuous edge 20D as
described with regard to the aforementioned embodiments.
[0084] The first member 10D comprises a first generally planar
portion 71 and a pair of upstanding portions 72 and 73, thereby
defining a generally U-shaped first member 10D. In the preferred
embodiment, upstanding portions 72 and 73 are fabricated by
bending, creasing or otherwise folding generally planar portion 71
on opposite ends thereof to create the generally U-shaped
configuration with end sections 72 and 73 disposed at an angle
.theta..sub.1D. Second member 30D includes a generally planar
portion 74 including edge 37D which is shaped or cut to correspond
in shape to edge 20D of first member 10D, thereby having angled
sections .theta..sub.2D, wherein .theta..sub.1D generally equals
.theta..sub.2D. In the preferred embodiment, portion 74 is cut to
form a corresponding generally U-shaped member 30D, including edge
37D, which corresponds in shape and size to edge 20D of member 10D.
First member 10D is attached to second member 30D by a continuous
flange 22D which is fabricated on edge 20D by bending, creasing or
otherwise folding the edge 20D as described previously. Of course,
a continuous flange 22B may also be disposed along continuous edge
37B and further, a pair of flanges (not shown) may also be used,
wherein each edge 20D and 37D has a flange disposed thereon.
[0085] In use, flashing member 70 provides a single flashing member
that simultaneously provides corner flashing and sill flashing of a
window, door, or the like with a single part. In use, flashing
device 70 is manufactured to have a length equal to the sill member
of the window or door it is designed to flash, thereby requiring
flashing members of different lengths for different sized windows.
However, this can inventively be avoided by cutting flashing device
70 in half, through sill portion 60D. In this respect, if the
flashing device is too long, sill portion 60D can be either cut
further, or overlapped to fit the corresponding frame. Alternately,
when the flashing device is too short for the frame, a cut is made
as described above and allows the corner pieces 2D to be disposed
in two corners of the frame, thereby providing a pair of
longitudinally extended flashing devices 2D to each lower corner of
the frame wherein the middle section of the sill, disposed between
each section 2D, remains unflashed. This middle section of the sill
can either be left unflashed or flashed with an additionally
flashing member (not shown).
[0086] Flashing device 70 may be manufactured utilizing the same
methods and materials as with regard to the aforementioned flashing
devices. In particular, a flexible material is typically used. Such
materials are commonly known within the art and may include, but
are not limited to, polymer sheeting and/or film. Although members
10D and 30D may be fabricated from dissimilar materials, in the
preferred embodiment the same, virtually non-permeable high
strength polyolefin sheet with a permeability of 0.3 perms or less,
is used. In the preferred embodiment, the method of fabricating
flashing device 70 is similar to the method for creating flashing
device 2B as discussed in detail previously. Further, as described
with regard to the other embodiments, flashing device 70 may be
made with varying geometries and angles to accommodate differing
window frame constructions as previously described.
[0087] The solutions offered by the invention herein have thus been
attained in an economical, practical, and facile manner. To wit, an
effective and convenient flashing device includes a continuous
flange that eliminates gaps thereby preventing leaks, a method for
fabricating the flashing device and a one-way valve flashing member
to allow water out of a construction but not into it. While
preferred embodiments and example configurations of the invention
have been herein illustrated, shown and described, it is to be
appreciated that various changes, rearrangements and modifications
may be made therein, without departing from the scope of the
invention as defined by the appended claims. It is intended that
the specific embodiments and configurations disclosed are
illustrative of the preferred and best modes for practicing the
invention, and should not be interpreted as limitations on the
scope of the invention as defined by the appended claims and it is
to be appreciated that various changes, rearrangements and
modifications may be made therein, without departing from the scope
of the invention as defined by the appended claims.
* * * * *